Rail repair equipment and repair method thereof

Abstract

The present invention discloses a rail repair operation equipment and a repair method thereof, belonging to the technical field of rail repair. The rail repair operation equipment includes a vehicle body, and the bottom of the vehicle body is provided with a measuring module, a profile repair module, a transition processing module and a smoothness recovery module. By integrating the measuring module, the profile repair module, the transition processing module and the smoothness recovery module on the vehicle body, a set of equipment can simultaneously repair the corrugation and profile of the rail, and can simultaneously handle the profile and smoothness problems of the rail, filling the deficiency of a single processing method in the prior art. The problem that the existing rail repair technology can often only handle a certain type of defect separately is solved; the vehicle body can drive the measurement module, the profile repair module, the transition processing module and the smoothness recovery module to move, which can optimize the rail repair operation process, reduce the number of round-trip grinding, and reduce labor costs and equipment use time.

Description

Technical Field

[0001] The invention belongs to the technical field of rail repair, and in particular relates to rail repair operation equipment and a repair method thereof. Background Art

[0002] With the rapid development of railway transportation, especially under high-speed and heavy-load conditions, the use of rails has deteriorated day by day. Common defects include cross-sectional problems such as fatigue cracks, spalling, fat edges, and longitudinal section defects such as wave wear and triangular pits. These defects not only affect driving safety and passenger comfort, but also significantly increase the economic cost of maintenance and replacement, bringing severe challenges to railway operations.

[0003] At present, rail repair mainly relies on rail grinding and milling technology. Although the traditional active rail grinding method can repair the rail profile, the smoothness of the rail after grinding is not high, and the effect and efficiency are low when repairing rail corrugation, especially it is difficult to deal with long wave corrugation. The high-speed rail grinding method has high smoothness after grinding and is suitable for removing rail corrugation, but its cutting amount is very small and cannot be used to repair the rail profile. Although milling technology has a large cutting capacity and can remove obvious defects, it has low operating efficiency and high cost, and can only use fixed rail milling profiles, which is difficult to adapt to the changing rail profile repair needs. In the existing rail repair technology, rail repair can often only deal with a certain type of problem alone, such as only removing rail corrugation, or it is suitable for repairing rail profile and removing rail damage and defects, but it is difficult to meet the needs of rail corrugation and profile repair that usually exist at the same time, and lacks a complete solution that can repair rail profile and smoothness at the same time.

[0004] Therefore, it is urgent to develop a rail repair equipment and repair method that can simultaneously repair the rail profile and restore the smoothness. This method can not only improve the repair efficiency and reduce operating costs, but also significantly improve the driving safety and riding comfort of the train. By effectively combining laser cutting technology with rail grinding technology and equipping it with an intelligent control system, the equipment will meet the high standards of modern railway transportation for rail maintenance and promote the development of rail maintenance technology. Summary of the invention

[0005] In view of the deficiencies in the above-mentioned background technology, the present invention aims to provide a rail repair operation equipment and a repair method thereof, which can simultaneously repair the rail profile and restore the rail smoothness, thereby solving the problem that the existing rail repair technology can often only handle a certain type of defect separately.

[0006] In order to achieve the above-mentioned object of the invention, the technical solution adopted by the present invention is as follows:

[0007] Provided is a rail repair equipment, which includes a vehicle body, wherein a measuring module, a profile repair module, a transition processing module and a smoothness recovery module are arranged at the bottom of the vehicle body; the measuring modules are each provided with a profile measuring sensor for measuring the complete profile of the rail and a corrugation measuring sensor for measuring the corrugation of the rail; the profile repair modules are each provided with a laser cutting head for cutting the rail; the transition processing modules are each provided with a first grindstone for grinding the rail; and the smoothness recovery module is provided with a second grindstone for grinding the rail.

[0008] The basic principle of the rail repair equipment in the present invention is that the vehicle body drives the measurement module to detect the profile and corrugation of the rail in real time, and generates a profile repair plan based on the profile and corrugation data of the rail; the laser cutting head on the profile repair module can quickly remove the damaged part and restore the designed profile of the rail. Compared with traditional grinding, laser cutting provides higher precision and efficiency, significantly shortening the repair time. This key technical solution enables the rail to return to the standard state in a short time, reducing the train downtime caused by track problems. The first grinding stone of the transition processing module rotates around its own axis, not only removing the heat-affected zone after laser cutting, but also forming lines on the surface of the rail that intersect with subsequent grinding. This design increases the grinding amount of grinding and further improves the smoothness of the track. Compared with traditional grinding, the present invention can achieve higher grinding efficiency in a shorter time, thereby effectively solving problems such as rail corrugation and improving ride comfort. The second grinding stone of the smoothness recovery module reciprocates in the horizontal direction, grinding the grinding position of the rail to restore the smoothness of the rail. The rail repair equipment of the present invention integrates a measuring module, a profile repair module, a transition processing module and a smoothness restoration module on a vehicle body, and through reasonable configuration of different rail repair technologies, active grinding can not only remove the heat affected zone after laser cutting, but also form lines on the rail surface that intersect with subsequent friction, significantly improving the grinding amount and efficiency of friction, and achieving a set of equipment that can simultaneously repair rail corrugation and profile, solving the problem that the existing rail repair technology can often only handle a certain type of defect separately; the vehicle body can drive the measurement module, the profile repair module, the transition processing module and the smoothness restoration module to move, which can optimize the rail repair operation process, reduce the number of round-trip grinding, and reduce labor costs and equipment usage time.

[0009] Furthermore, a transition processing module, a profile repair module and a measurement module are symmetrically arranged on both sides of the smoothness recovery module along the length direction of the vehicle body. The above arrangement enables the vehicle to operate in both directions, thereby improving the efficiency of rail repair operations.

[0010] Furthermore, as a specific setting method of the measurement module, each measurement module includes a mounting bracket fixedly connected to the bottom of the vehicle body, the mounting bracket is in a "door"-shaped structure, and two contour measurement sensors are arranged at both ends of the mounting bracket. The two contour measurement sensors are fixedly arranged on both sides of the rail at a fixed angle; the contours of both sides of the rail are measured, and then spliced ​​into a complete contour through an algorithm.

[0011] There is an installation box at both ends of the outer end surface of the mounting bracket. Four corrugation measurement sensors are installed in each installation box. The four corrugation measurement sensors are located above the rail. The corrugation measurement sensors are laser displacement sensors. The four corrugation measurement sensors are distributed above the rail at a specific interval and measure the rail corrugation by multi-point chord measurement method.

[0012] Furthermore, as a specific arrangement of the profile repair module, each profile repair module includes two first transverse guide rails and a first rack, and the two first transverse guide rails and the first rack are fixedly connected to the bottom of the vehicle body; two profile repair assemblies are slidably connected to the two first transverse guide rails and the first rack. The two first transverse guide rails and the first rack can ensure the smooth operation of the profile repair assembly, and the two profile repair assemblies are arranged at intervals on the left and right, each responsible for processing the rails on one side.

[0013] Specifically, each profile repair assembly includes a first transverse shift seat, on which a first upper slider, a first transverse motor and a first vertical motor are provided; the first upper slider is arranged on the top of the first transverse shift seat and is slidably connected to the first transverse guide rail.

[0014] A first gear meshing with the first rack is arranged on the output shaft of the first transverse motor. When the first transverse motor rotates, it can drive the profile repair component to move laterally on two first transverse guide rails and a first rack to adapt to different cutting angles.

[0015] The first vertical motor is vertically arranged on the top of the first transverse seat, and a first lead screw is connected to the output shaft of the first vertical motor through a first coupling, a first lead screw nut is threadedly connected to the first lead screw, and a first vertical sliding seat is connected to the first lead screw nut, and the first vertical sliding seat is slidably connected to the first transverse seat through a first lower slider and a first vertical guide rail; the number of the first vertical guide rails is two, which are symmetrically arranged on the first transverse seat, and two first lower sliders that slide with the two vertical guide rails are fixedly arranged on the first vertical sliding seat to achieve a sliding connection between the first vertical sliding seat and the first transverse seat. When the first vertical motor rotates, the first lead screw can be driven to rotate through the first coupling, and the rotation of the first lead screw drives the first lead screw nut to move in the vertical direction, thereby realizing the up and down movement of the first vertical sliding seat.

[0016] A first rotating shaft is vertically arranged at the bottom of the first vertical sliding seat, a rotating seat is fixedly connected to the bottom end of the first rotating shaft, a second rotating shaft is horizontally arranged on the rotating seat, and a laser cutting head is fixedly connected to the end of the second rotating shaft. Specifically, both the first rotating shaft and the second rotating shaft can be driven to rotate by a servo motor, which belongs to the prior art and is not elaborated in detail here, so as to adjust the circumferential angle of the rotating seat and the cutting angle of the laser cutting head connected to the second rotating shaft, so as to meet the requirements of cutting rails at different angles.

[0017] Furthermore, a support plate is provided on the laser cutting head, and a copper block is provided on the support plate, which is located in front of the laser cutting head, and the rail to be cut is located between the laser cutting head and the copper block. The copper block has a strong absorption capacity for laser and is difficult to be cut, which can play a protective role and prevent the laser cutting head from cutting other components except the rail.

[0018] Furthermore, as a specific arrangement of the transition processing module, each transition processing module includes two second transverse guide rails and a second rack, and the two second transverse guide rails and the second rack are fixedly connected to the bottom of the vehicle body; two transition processing assemblies are slidably connected to the two second transverse guide rails and the second rack. The two second transverse guide rails and the second rack can ensure the smooth operation of the transition processing assembly; the two transition processing assemblies are arranged at intervals on the left and right, and each is responsible for the processing of one side of the rail.

[0019] Each transition processing assembly includes a second transverse shift seat, on which a second upper slider, a second transverse motor and a second vertical motor are arranged; the second upper slider is arranged on the top of the second transverse shift seat and is slidably connected to the second transverse guide rail.

[0020] The output shaft of the second transverse motor is provided with a second gear meshing with the second rack; when the second transverse motor rotates, it can drive the transition processing assembly to move transversely to adapt to different grinding angles;

[0021] The second vertical motor is vertically arranged on the top of the second transverse movement seat. A second lead screw is connected to the output shaft of the second vertical motor through a second coupling. A second lead screw nut is threadedly connected to the second lead screw. The second lead screw nut is connected to a second vertical sliding seat. The second vertical sliding seat is slidably connected to the second transverse movement seat through a second lower slider and a second vertical guide rail.

[0022] There are two second vertical guide rails, which are symmetrically arranged on the first transverse seat. Two second lower sliders are fixedly arranged on the second vertical sliding seat, which are slidably matched with the two second vertical guide rails, so as to realize the sliding connection between the second vertical sliding seat and the second transverse seat. When the second vertical motor rotates, the second lead screw can be driven to rotate through the second coupling, and the rotation of the second lead screw drives the second lead screw nut to move in the vertical direction, so as to realize the up and down movement of the second vertical sliding seat.

[0023] Two transition brackets are fixedly connected to the bottom of the second vertical sliding seat, and a first movable seat is rotatably arranged between the two transition brackets. A first rotating cylinder is horizontally arranged on the outside of one of the transition brackets, and the rotating axis of the first rotating cylinder passes through the transition bracket and is fixedly connected to the first movable seat, driving the first movable seat to rotate circumferentially to achieve the purpose of adjusting the grinding angle.

[0024] A first center hole is provided on the first movable seat, and a first grindstone seat is provided in the first center hole. The first grindstone seat can slide up and down along the first center hole. Two first clamping cylinders are symmetrically provided on the first movable seat. The piston rod of the first clamping cylinder is fixedly connected to the first grindstone seat for pushing the first grindstone seat to slide. A driving motor is provided at the rear end of the first grindstone seat, and the stator part of the driving motor is fixed to the first grindstone seat. The rotor part of the driving motor is connected to a connecting shaft, which passes through the first grindstone seat, and the end of the connecting shaft is connected to the first grindstone.

[0025] When the transition processing module is grinding the rail, the piston rod of the first clamping cylinder extends to push the first grinding stone seat downward, so that the first grinding stone on the first grinding stone seat is pressed tightly against the rail; the driving motor rotates to drive the connecting shaft to rotate synchronously, driving the first grinding stone to rotate, thereby realizing the grinding of the rail.

[0026] Furthermore, the ends of the two transition brackets are connected to a transition connection seat, and a first rotary cylinder and a first rotary encoder are respectively provided on the two transition connection seats. The rotary encoder can detect the rotation angle of the first movable seat, thereby obtaining the current grinding angle; bearings and sleeves are provided between the connecting shaft and the first grindstone seat. Specifically, the connecting shaft is rotatably connected to the first grindstone seat through a large bearing and a small bearing, and the large bearing and the small bearing are positioned through the sleeve.

[0027] Furthermore, as a specific setting method of the smoothness recovery module, the smoothness recovery module includes a support frame, and a traction rod is arranged on both sides of the support frame. The two ends of each traction rod are respectively hinged to the side wall of the support frame and the bottom of the vehicle body. During operation, the traction smoothness recovery module moves synchronously with the vehicle body.

[0028] Four downward pressure cylinders are vertically arranged at the four corners of the support frame. The fixed ends of the four downward pressure cylinders are fixedly connected to the bottom of the vehicle body, and the piston ends are fixedly connected to the support frame. During operation, the downward pressure cylinders press the operating support frame down onto the rails.

[0029] Guide wheels for cooperating with the rails are arranged at the four corners of the bottom of the support frame, which play a guiding role during operation and prevent the operating mechanism from leaving the track.

[0030] The support frame is provided with 4 groups of first guide shafts and 4 linear reciprocating cylinders. Each group of first guide shafts is matched with a linear reciprocating cylinder. There are two first guide shafts in each group. The first guide shafts and the linear reciprocating cylinders are arranged along the length direction of the vehicle body. The two first guide shafts are connected with a smoothness operation component through the first guide shaft slider. Each linear reciprocating cylinder is a bidirectional hydraulic cylinder. The bidirectional output shafts of the linear reciprocating cylinders are fixedly connected to the smoothness operation component. The fixed end of the linear reciprocating cylinder is fixedly connected to the support frame. A plurality of second grinding stones are arranged on the smoothness operation component. The linear reciprocating motion can be realized by controlling the oil inlet direction of the linear reciprocating cylinder, thereby driving the smoothness recovery module and the plurality of second grinding stones thereon to reciprocate back and forth to realize the grinding of the rails.

[0031] Furthermore, as a specific setting method of the smoothness operation component, each smoothness operation component includes a main frame with a top fixedly connected to the first guide shaft slider and the bidirectional output shaft of the linear reciprocating cylinder, and multiple second guide shafts and multiple linear cylinders are arranged on the main frame. The second guide shafts and the linear cylinders are in a one-to-one matching relationship, and the axial direction of each second guide shaft and the extension and retraction direction of the piston rod of the linear cylinder are perpendicular to the length direction of the rail. Each second guide shaft is slidably connected to a connecting frame through the second guide shaft slider, and the output end of the linear cylinder is fixedly connected to the second guide shaft slider; the connecting frame is realized to slide linearly on the second guide shaft.

[0032] The bottom end of the connecting frame is connected to a second rotating cylinder and a transition seat. A second movable seat is connected to the piston rod of the second rotating cylinder. The piston rod of the second rotating cylinder can rotate within the range of 0-360° relative to the cylinder barrel, driving the second movable seat to rotate, so as to achieve the purpose of adjusting the grinding angle.

[0033] A second rotary encoder is arranged on the transition seat, and a rotating shaft of the second rotary encoder is fixedly connected to the second movable seat. When the second movable seat rotates, the second rotary encoder can detect the rotation angle.

[0034] The second movable seat is provided with a second center hole, and a second grinding stone seat is provided in the second center hole. The second grinding stone seat can slide up and down along the second center hole. Two second clamping oil cylinders are symmetrically provided on the second movable seat. The piston rod of the second clamping oil cylinder is fixedly connected to the second grinding stone seat, and is used to push the second grinding stone seat to slide. A second grinding stone is provided at the bottom of the second grinding stone seat; a plurality of second grinding stones are arranged on both sides and the top of the rail respectively. When the smoothness operation assembly grinds the rail, the second clamping oil cylinder extends to push the second grinding stone seat downward, so that the second grinding stone on the second grinding stone seat is pressed tightly against the rail, and moves back and forth in a straight line with the main frame or the connecting frame, so as to realize the grinding of the rail.

[0035] The present invention also provides a repair method for rail repair equipment, which comprises:

[0036] Step 1: The vehicle body moves in the working direction, and the measuring module located in the front of the driving direction synchronously measures the profile and corrugation of the rail, transmits the profile and corrugation data of the rail to the control system and generates a profile repair plan;

[0037] Step 2: The vehicle body drives the profile repair module to move to the defective position of the rail, and the laser cutting head on the profile repair module is adjusted to a specified angle to cut the defective position of the rail according to the profile repair plan;

[0038] Step 3: The vehicle body drives the transition processing module located at the rear of the profile repair module to move to the rail laser cutting position, and the transition processing module is started to rotate the first grindstone to grind the rail laser cutting position to remove the heat affected zone of the rail after laser cutting, and at the same time form a grinding mark with a fixed angle with the length direction of the rail, thereby increasing the grinding amount of the smoothness recovery module;

[0039] Step 4: The vehicle body drives the smoothness recovery module located at the rear of the transition processing module to move to the rail grinding position, and the smoothness recovery module is started to make the second grinding stone reciprocate and linearly move to grind the rail grinding position to restore the smoothness of the rail;

[0040] Step 5: The transition processing module and the profile repair module located at the rear of the smoothness recovery module do not work, and the measurement module located at the end measures the processed rails again to evaluate the quality of the rail repair operation and complete the rail repair operation.

[0041] The beneficial effects of the present invention are:

[0042] 1. The rail repair equipment and repair method of the present invention can simultaneously solve the problems of rail profile and smoothness, filling the gap of the single treatment method in the prior art. The modular design of the equipment is convenient for operation and maintenance, improves the overall work efficiency, and provides a more reliable technical guarantee for railway operation.

[0043] 2. The profile repair module of a rail repair equipment in the present invention uses laser cutting technology to quickly remove the damaged part and restore the designed profile of the rail. Compared with traditional grinding, laser cutting provides higher precision and efficiency, significantly shortening the repair time. This key technical solution enables the rail to be restored to the standard state in a short time, reducing the train downtime caused by track problems.

[0044] 3. A rail repair equipment in the present invention, the transition processing module integrates active grinding technology, which not only removes the heat-affected zone after laser cutting, but also forms lines on the rail surface that intersect with subsequent friction. This design increases the amount of grinding and further improves the smoothness of the track. Compared with traditional grinding, the present invention can achieve higher grinding efficiency in a shorter time, thereby effectively solving problems such as rail corrugation and improving ride comfort. The combination of laser cutting and active grinding makes the overall repair process more efficient, reduces maintenance frequency, and reduces long-term maintenance costs. In addition, the risk of accidents caused by rail defects is reduced, thereby reducing safety hazards in railway operations.

[0045] 4. In the rail repair equipment of the present invention, a transition processing module, a profile repair module and a measurement module are symmetrically arranged on both sides of the smoothness recovery module along the length direction of the vehicle body, so that the vehicle can operate in both directions, optimize the operation process, reduce the number of round-trip grinding, and reduce labor costs and equipment usage time. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 This is a schematic diagram of the front view of the rail repair equipment.

[0047] Figure 2 This is a schematic diagram of the front view structure of the measurement module.

[0048] Figure 3 A side view schematic diagram of the measurement module.

[0049] Figure 4 Schematic diagram of the structure of the profile repair module.

[0050] Figure 5 It is a schematic diagram of the front view structure of a single profile repair component.

[0051] Figure 6 Schematic diagram of the test structure of a single profile repair component.

[0052] Figure 7 It is a structural diagram of the transition processing module.

[0053] Figure 8It is a schematic diagram of the front view structure of a single transition processing component.

[0054] Fig. 9 A side view of a single transition processing component Figure 2 .

[0055] Fig.10 Schematic diagram of the 3D structure of rail grinding for a single transition processing component.

[0056] Fig.11 It is a structural schematic diagram of the first movable seat.

[0057] Fig.12 Schematic diagram of the internal structure of the first movable seat.

[0058] Fig.13 It is a schematic diagram of the front view structure of the smoothness recovery module.

[0059] Fig.14 Schematic diagram of the top view of the smoothness recovery module.

[0060] Fig.15 It is a schematic diagram of the front view structure of a single smooth operation component.

[0061] Fig.16 Schematic diagram of the internal structure of a single smooth operation component.

[0062] Among them, 1. Vehicle body;

[0063] 2. Measuring module; 21. Mounting bracket; 22. Contour measurement sensor; 23. Corrugation measurement sensor;

[0064] 3. Profile repair module; 30. Profile repair assembly; 31. First transverse guide rail; 32. First rack; 34. First transverse motor; 35. First gear; 36. First transverse seat; 37. First upper slider; 38. First vertical motor; 39. First coupling; 310. First lead screw; 311. First vertical guide rail; 312. First lower slider; 313. First lead screw nut; 314. First vertical sliding seat; 315. First rotating shaft; 316. Second rotating shaft; 317. Support plate; 318. Copper block; 319. Laser cutting head;

[0065] 4. Transition processing module; 40. Transition processing assembly; 41. Second gear; 42. Second transverse motor; 43. Second upper slider; 44. Second transverse seat; 45. Second vertical guide rail; 46. Second coupling; 47. Second vertical motor; 48. Second lead screw; 49. Second lower slider; 410. Second lead screw nut; 411. Second vertical sliding seat; 412. Transition bracket; 413. First rotary encoder; 414. Drive motor; 415. First grindstone seat; 416. First movable seat; 417. First rotary oil cylinder; 418. First clamping oil cylinder; 419. First grindstone; 420. Second transverse guide rail; 421. Second rack; 422. Transition connection seat; 423. Connecting shaft; 424. Large bearing; 425. Bushing; 426. Small bearing;

[0066] 5. Smoothness recovery module; 51. First guide shaft slider; 52. Traction rod; 53. Down-pressing cylinder; 54. Guide wheel; 55. Support frame; 56. Smoothness operation assembly; 57. First guide shaft; 58. Linear reciprocating cylinder;

[0067] 561, main frame; 562, second guide shaft; 563, second guide shaft slider; 564, connecting frame; 565, second rotary cylinder; 566, transition seat; 567, second rotary encoder; 568, second movable seat; 569, second grindstone seat; 5610, second pressing cylinder; 5611, second grindstone; 5612, linear cylinder;

[0068] 6. Rails. DETAILED DESCRIPTION

[0069] The specific implementation modes of the present invention are described below so that those skilled in the art can understand the present invention. However, it should be clear that the present invention is not limited to the scope of the specific implementation modes. For those of ordinary skill in the art, as long as various changes are within the spirit and scope of the present invention as defined and determined by the attached claims, these changes are obvious, and all inventions and creations utilizing the concept of the present invention are protected.

[0070] like Figure 1 As shown, the present scheme provides a rail repair operation equipment, which includes a vehicle body 1, and a measuring module 2, a profile repair module 3, a transition processing module 4 and a smoothness restoration module 5 are arranged at the bottom of the vehicle body 1; the measuring module 2 is provided with a profile measurement sensor 22 for measuring the complete profile of the rail 6 and a wave grinding measurement sensor 23 for measuring the wave grinding of the rail 6; the profile repair module 3 is provided with a laser cutting head 319 for cutting the rail 6; the transition processing module 4 is provided with a first grindstone 419 for grinding the rail 6; the smoothness restoration module 5 is provided with a second grindstone 5611 for grinding the rail 6.

[0071] The vehicle body 1 drives the measuring module 2 to perform real-time detection of the profile and corrugation of the rail 6, and generates a profile repair plan based on the profile and corrugation data of the rail 6; the laser cutting head 319 on the profile repair module 3 can quickly remove the damaged part and restore the designed profile of the rail 6. Compared with traditional grinding, laser cutting provides higher precision and efficiency, and significantly shortens the repair time. This key technical solution enables the rail 6 to return to the standard state in a short time, reducing the train downtime caused by track problems. The first grindstone 419 of the transition processing module 4 rotates around its own axis, which not only removes the heat-affected zone after laser cutting, but also forms lines on the surface of the rail 6 that intersect with subsequent grinding. This design increases the grinding amount of grinding and further improves the smoothness of the track. Compared with traditional grinding, the present invention can achieve higher grinding efficiency in a shorter time, thereby effectively solving problems such as rail corrugation and improving riding comfort. The second grinding stone 5611 of the smoothness recovery module 5 reciprocates in the horizontal direction to perform grinding operations on the grinding position of the rail 6 to restore the smoothness of the rail 6. The rail 6 repair operation equipment of the present invention integrates the measuring module 2, the profile repair module 3, the transition processing module 4 and the smoothness recovery module 5 on the vehicle body 1, so that a set of equipment can simultaneously repair the corrugation and profile of the rail 6, solving the problem that the existing rail 6 repair technology can only handle a certain type of defect separately; the vehicle body 1 can drive the measuring module 2, the profile repair module 3, the transition processing module 4 and the smoothness recovery module 5 to move, which can optimize the rail 6 repair operation process, reduce the number of round-trip grinding, and reduce labor costs and equipment use time.

[0072] Furthermore, a transition processing module 4, a profile repair module 3 and a measurement module 2 are symmetrically arranged on both sides of the smoothness recovery module 5 along the length direction of the vehicle body 1. The above arrangement enables the vehicle to operate in both directions and improves the efficiency of the rail 6 repair operation.

[0073] like Figure 1~Figure 3 As shown, as a specific setting method of the measurement module 2, each measurement module 2 includes a mounting bracket 21 fixedly connected to the bottom of the vehicle body 1, the mounting bracket 21 is in a "door" shape, and two contour measurement sensors 22 are arranged at both ends of the mounting bracket 21. The two contour measurement sensors 22 are fixedly arranged on both sides of the rail 6 at a fixed angle; the contours of both sides of the rail 6 are measured, and then spliced ​​into a complete contour through an algorithm.

[0074] An installation box is provided at both ends of the outer end surface of the installation bracket 21, and four corrugation measurement sensors 23 are provided in each installation box, and the four corrugation measurement sensors 23 are located above the rail 6. The corrugation measurement sensors 23 are laser displacement sensors, and the four corrugation measurement sensors 23 are distributed above the rail 6 at a specific interval, and the corrugation of the rail 6 is measured by a multi-point chord measurement method.

[0075] Furthermore, if Figure 1 and Figure 4~Figure 6 As shown, as a specific arrangement of the profile repair module 3, each profile repair module 3 includes two first transverse guide rails 31 and a first rack 32, and the two first transverse guide rails 31 and the first rack 32 are fixedly connected to the bottom of the vehicle body 1; two profile repair assemblies 30 are slidably connected to the two first transverse guide rails 31 and the first rack 32. The two first transverse guide rails 31 and the first rack 32 can ensure that the profile repair assembly 30 runs smoothly, and the two profile repair assemblies 30 are arranged at intervals on the left and right, and each is responsible for processing the rail 6 on one side.

[0076] Specifically, each profile repair assembly 30 includes a first transverse shift seat 36 , on which a first upper slider 37 , a first transverse motor 34 and a first vertical motor 38 are provided; the first upper slider 37 is arranged on the top of the first transverse shift seat 36 and is slidably connected to the first transverse guide rail 31 .

[0077] A first gear 35 meshing with the first rack 32 is disposed on the output shaft of the first transverse motor 34. When the first transverse motor 34 rotates, it can drive the profile repair assembly 30 to move transversely on two first transverse guide rails 31 and a first rack 32 to adapt to different cutting angles.

[0078] The first vertical motor 38 is vertically arranged on the top of the first transverse seat 36. A first lead screw 310 is connected to the output shaft of the first vertical motor 38 through a first coupling 39. A first lead screw nut 313 is threadedly connected to the first lead screw 310. A first vertical sliding seat 314 is connected to the first lead screw nut 313. The first vertical sliding seat 314 is slidably connected to the first transverse seat 36 through a first lower slider 312 and a first vertical guide rail 311. There are two first vertical guide rails 311, which are symmetrically arranged on the first transverse seat 36. Two first lower sliders 312 that are slidably matched with the two vertical guide rails are fixedly arranged on the first vertical sliding seat 314, so that the first vertical sliding seat 314 is slidably connected to the first transverse seat 36. When the first vertical motor 38 rotates, the first lead screw 310 can be driven to rotate through the first coupling 39. The rotation of the first lead screw 310 drives the first lead screw nut 313 to move in the vertical direction, thereby realizing the up and down movement of the first vertical sliding seat 314.

[0079] A first rotating shaft 315 is vertically arranged at the bottom of the first vertical sliding seat 314, a rotating seat is fixedly connected to the bottom end of the first rotating shaft 315, a second rotating shaft 316 is horizontally arranged on the rotating seat, and a laser cutting head 319 is fixedly connected to the end of the second rotating shaft 316. Specifically, both the first rotating shaft 315 and the second rotating shaft 316 can be driven to rotate by a servo motor, which belongs to the prior art and is not elaborated in detail here, so as to adjust the circumferential angle of the rotating seat and the cutting angle of the laser cutting head 319 connected to the second rotating shaft 316, so as to meet the cutting operation requirements of the rail 6 at different angles.

[0080] Furthermore, a support plate 317 is provided on the laser cutting head 319, and a copper block 318 is provided on the support plate 317, which is located directly in front of the laser cutting head 319, and the rail 6 to be cut is located between the laser cutting head 319 and the copper block 318. The copper block 318 has a strong absorption capacity for laser and is difficult to be cut, which can play a protective role and prevent the laser cutting head 319 from laser cutting other components except the rail 6.

[0081] like Figure 1 and Figure 7 to Figure 12 As shown, as a specific arrangement of the transition processing module 4, each transition processing module 4 includes two second transverse guide rails 420 and a second rack 421, and the two second transverse guide rails 420 and the second rack 421 are fixedly connected to the bottom of the vehicle body 1; two transition processing assemblies 40 are slidably connected to the two second transverse guide rails 420 and the second rack 421. The two second transverse guide rails 420 and the second rack 421 can ensure that the transition processing assembly 40 runs smoothly; the two transition processing assemblies 40 are arranged at intervals on the left and right, and each is responsible for processing the steel rail 6 on one side.

[0082] Each transition processing assembly 40 includes a second transverse shift seat 44 , on which a second upper slider 43 , a second transverse motor 42 and a second vertical motor 47 are disposed; the second upper slider 43 is disposed on the top of the second transverse shift seat 44 and is slidably connected to the second transverse guide rail 420 .

[0083] The output shaft of the second transverse motor 42 is provided with a second gear 41 meshing with the second rack 421; when the second transverse motor 42 rotates, it can drive the transition processing assembly 40 to move transversely to adapt to different grinding angles;

[0084] The second vertical motor 47 is vertically arranged on the top of the second transverse displacement seat 44, and a second lead screw 48 is connected to the output shaft of the second vertical motor 47 through a second coupling 46, and a second lead screw nut 410 is threadedly connected to the second lead screw 48, and the second lead screw nut 410 is connected to a second vertical sliding seat 411, and the second vertical sliding seat 411 is slidably connected to the second transverse displacement seat 44 through a second lower sliding block 49 and a second vertical guide rail 45.

[0085] There are two second vertical guide rails 45, which are symmetrically arranged on the first transverse seat. Two second lower sliders 49 that are slidably matched with the two second vertical guide rails 45 are fixedly arranged on the second vertical sliding seat 411, so as to realize the sliding connection between the second vertical sliding seat 411 and the second transverse seat 44. When the second vertical motor 47 rotates, the second lead screw 48 can be driven to rotate through the second coupling 46, and the rotation of the second lead screw 48 drives the second lead screw nut 410 to move in the vertical direction, so as to realize the up and down movement of the second vertical sliding seat 411.

[0086] Two transition brackets 412 are fixedly connected to the bottom of the second vertical sliding seat 411, and a first movable seat 416 is rotatably arranged between the two transition brackets 412. A first rotating cylinder 417 is horizontally arranged on the outside of one of the transition brackets 412, and the rotating axis of the first rotating cylinder 417 passes through the transition bracket 412 and is fixedly connected to the first movable seat 416, driving the first movable seat 416 to rotate circumferentially to achieve the purpose of adjusting the grinding angle.

[0087] A first center hole is provided on the first movable seat 416, and a first grindstone seat 415 is provided in the first center hole. The first grindstone seat 415 can slide up and down along the first center hole. Two first clamping cylinders 418 are symmetrically provided on the first movable seat 416. The piston rod of the first clamping cylinder 418 is fixedly connected to the first grindstone seat 415, and is used to push the first grindstone seat 415 to slide; a driving motor 414 is provided at the rear end of the first grindstone seat 415, and the stator part of the driving motor 414 is fixed to the first grindstone seat 415, and the rotor part of the driving motor 414 is connected to a connecting shaft 423, and the connecting shaft 423 passes through the first grindstone seat 415, and the end of the connecting shaft 423 is connected to the first grindstone 419.

[0088] When the transition processing module 4 grinds the rail 6, the piston rod of the first clamping cylinder 418 extends to push the first grindstone seat 415 downward, so that the first grindstone 419 on the first grindstone seat 415 is pressed tightly against the rail 6; the driving motor 414 rotates to drive the connecting shaft 423 to rotate synchronously, driving the first grindstone 419 to rotate, thereby achieving the grinding of the rail 6.

[0089] Furthermore, the ends of the two transition brackets 412 are connected to a transition connection seat 422, and the two transition connection seats 422 are respectively provided with a first rotating cylinder 417 and a first rotary encoder 413, and the rotary encoder can detect the rotation angle of the first movable seat 416, so as to obtain the current grinding angle; a bearing and a sleeve 425 are arranged between the connecting shaft 423 and the first grindstone seat 415, specifically, the connecting shaft 423 is rotatably connected to the first grindstone seat 415 through a large bearing 424 and a small bearing 426, and the large bearing 424 and the small bearing 426 are positioned through the sleeve 425.

[0090] like Figure 1 and Figure 13~Figure 16 As shown, as a specific setting method of the smoothness recovery module 5, the smoothness recovery module 5 includes a support frame 55, and a traction rod 52 is arranged on both sides of the support frame 55. The two ends of each traction rod 52 are respectively hinged to the side wall of the support frame 55 and the bottom of the vehicle body 1. During operation, the traction smoothness recovery module 5 moves synchronously with the vehicle body 1.

[0091] Four downward-pressing cylinders 53 are vertically arranged at the four corners of the support frame 55 , the fixed ends of the four downward-pressing cylinders 53 are fixedly connected to the bottom of the vehicle body 1 , and the piston ends are fixedly connected to the support frame 55 . During operation, the downward-pressing cylinders 53 press the operating support frame 55 down onto the rail 6 .

[0092] Guide wheels 54 for cooperating with the rails 6 are arranged at the four corners of the bottom of the support frame 55 to guide the operation mechanism during operation and prevent it from leaving the track.

[0093] The support frame 55 is provided with 4 groups of first guide shafts 57 and 4 linear reciprocating cylinders 58. Each group of first guide shafts 57 is matched with a linear reciprocating cylinder 58. The number of each group of first guide shafts 57 is two. The first guide shafts 57 and the linear reciprocating cylinders 58 are both arranged along the length direction of the vehicle body 1. The two first guide shafts 57 are connected with a smoothness operation component 56 through the first guide shaft slider 51. Each linear reciprocating cylinder 58 is a bidirectional hydraulic cylinder. The bidirectional output shafts of the linear reciprocating cylinders 58 are fixedly connected to the smoothness operation component 56. The fixed end of the linear reciprocating cylinder 58 is fixedly connected to the support frame 55. A plurality of second grinding stones 5611 are arranged on the smoothness operation component 56. The linear reciprocating cylinder 58 can realize linear reciprocating motion by controlling the oil inlet direction of the linear reciprocating cylinder 58, thereby driving the smoothness recovery module 5 and the plurality of second grinding stones 5611 thereon to reciprocate back and forth, thereby realizing the grinding of the rail 6.

[0094] Furthermore, as a specific setting method of the smoothness operation component 56, each smoothness operation component 56 includes a main frame 561 whose top is fixedly connected to the first guide shaft slider 51 and the bidirectional output shaft of the linear reciprocating cylinder 58, and a plurality of second guide shafts 562 and a plurality of linear cylinders 5612 are arranged on the main frame 561. The second guide shafts 562 and the linear cylinders 5612 are in a one-to-one matching relationship, and the axial direction of each second guide shaft 562 and the extension and retraction direction of the piston rod of the linear cylinder 5612 are perpendicular to the length direction of the rail 6. A connecting frame 564 is slidably connected to each second guide shaft 562 through a second guide shaft slider 563, and the output end of the linear cylinder 5612 is fixedly connected to the second guide shaft slider 563; the connecting frame 564 is realized to slide linearly on the second guide shaft 562.

[0095] The bottom end of the connecting frame 564 is connected to a second rotating cylinder 565 and a transition seat 566. A second movable seat 568 is connected to the piston rod of the second rotating cylinder 565. The piston rod of the second rotating cylinder 565 can rotate within a range of 0-360° relative to the cylinder barrel, driving the second movable seat 568 to rotate, so as to adjust the grinding angle.

[0096] A second rotary encoder 567 is disposed on the transition seat 566 , and a rotating shaft of the second rotary encoder 567 is fixedly connected to the second movable seat 568 . When the second movable seat 568 rotates, the second rotary encoder 567 can detect the angle of rotation.

[0097] The second movable seat is provided with a second center hole, and a second grinding stone seat 569 is provided in the second center hole. The second grinding stone seat 569 can slide up and down along the second center hole. Two second clamping oil cylinders 5610 are symmetrically provided on the second movable seat. The piston rod of the second clamping oil cylinder 5610 is fixedly connected to the second grinding stone seat 569, and is used to push the second grinding stone seat 569 to slide. A second grinding stone 5611 is provided at the bottom of the second grinding stone seat 569; a plurality of second grinding stones 5611 are respectively arranged on both sides and the top of the rail 6. When the smoothness operation component 56 grinds the rail 6, the second clamping oil cylinder 5610 extends to push the second grinding stone seat 569 downward, so that the second grinding stone 5611 on the second grinding stone seat 569 is pressed against the rail 6, and performs linear reciprocating motion with the main frame 561 or the connecting frame 564, thereby realizing the grinding of the rail 6.

[0098] The present invention also provides a repair method for rail repair equipment, which comprises:

[0099] Step 1, the vehicle body 1 moves in the working direction, and the measuring module 2 located in the front of the driving direction synchronously measures the profile and corrugation of the rail 6, and transmits the profile and corrugation data of the rail 6 to the control system and generates a profile repair plan;

[0100] Step 2: The vehicle body 1 drives the profile repair module 3 to move to the defective position of the rail 6, and the laser cutting head 319 on the profile repair module 3 is adjusted to a specified angle to cut the defective position of the rail 6 according to the profile repair plan;

[0101] Step 3, the vehicle body 1 drives the transition processing module 4 located at the rear of the profile repair module 3 to move to the laser cutting position of the rail 6, and starts the transition processing module 4 to rotate the first grindstone 419 to grind the laser cutting position of the rail 6, remove the heat affected zone of the rail 6 after laser cutting, and at the same time form a grinding mark with a fixed angle with the length direction of the rail 6, and increase the grinding amount of the smoothness recovery module 5;

[0102] Step 4: The vehicle body 1 drives the smoothness recovery module 5 located at the rear of the transition processing module 4 to move to the grinding position of the rail 6, and starts the smoothness recovery module 5 to make the second grindstone 5611 reciprocate linearly to grind the grinding position of the rail 6 to restore the smoothness of the rail 6;

[0103] Step 5: The transition processing module 4 and the profile repairing module 3 located at the rear of the smoothness recovery module 5 do not work, and the measuring module 2 located at the end measures the processed rail 6 again to evaluate the quality of the rail 6 repair operation and complete the rail 6 repair operation.

[0104] In the above method, the profile repair module 3 uses laser cutting technology to quickly remove the damaged part and restore the designed profile of the rail 6. Compared with traditional grinding, laser cutting provides higher precision and efficiency, significantly shortening the repair time. This key technical solution enables the rail 6 to be restored to the standard state in a short time, reducing the train downtime caused by track problems.

[0105] The active grinding technology integrated in the transition processing module 4 not only removes the heat-affected zone after laser cutting, but also forms lines on the surface of the rail 6 that intersect with the subsequent grinding. This design increases the amount of grinding and further improves the smoothness of the track. Compared with traditional grinding, the present invention can achieve higher grinding efficiency in a shorter time, thereby effectively solving problems such as rail corrugation and improving ride comfort. The combination of laser cutting and active grinding makes the overall repair process more efficient, reduces the maintenance frequency, and reduces long-term maintenance costs. In addition, the risk of accidents caused by defects in the rail 6 is reduced, thereby reducing safety hazards in railway operations.

Claims

1. A rail repair equipment, characterized in that: It includes a vehicle body, and a measurement module, a profile repair module, a transition processing module and a smoothness recovery module are arranged at the bottom of the vehicle body; The measuring modules are provided with a profile measuring sensor for measuring the complete profile of the rail and a corrugation measuring sensor for measuring the corrugation of the rail; The profile repair modules are each provided with a laser cutting head for cutting the rails; The transition processing modules are each provided with a first grinding stone for grinding the rails; The smoothness recovery module is provided with a second grinding stone for grinding the rail; A transition processing module, a profile repair module and a measurement module are symmetrically arranged on both sides of the smoothness recovery module along the length direction of the vehicle body; Each of the profile repair modules comprises two first transverse guide rails and a first rack, and the two first transverse guide rails and the first rack are fixedly connected to the bottom of the vehicle body; the two first transverse guide rails and the first rack are slidably connected to two profile repair components; Each of the profile repairing components comprises a first transverse shift seat, on which a first upper slider, a first transverse motor and a first vertical motor are arranged; the first upper slider is arranged on the top of the first transverse shift seat and is slidably connected to the first transverse guide rail; A first gear meshing with a first rack is provided on the output shaft of the first horizontal motor; the first vertical motor is vertically arranged on the top of the first transverse movement seat, a first lead screw is connected to the output shaft of the first vertical motor through a first coupling, a first lead screw nut is threadedly connected to the first lead screw, the first lead screw nut is connected to a first vertical sliding seat, and the first vertical sliding seat is slidably connected to the first transverse movement seat through a first lower slider and a first vertical guide rail; a first rotating shaft is vertically arranged at the bottom of the first vertical sliding seat, a rotating seat is fixedly connected to the bottom end of the first rotating shaft, a second rotating shaft is horizontally arranged on the rotating seat, and the laser cutting head is fixedly connected to the end of the second rotating shaft; The laser cutting head is provided with a support plate, and a copper block is provided on the support plate and is located directly in front of the laser cutting head. The rail to be cut is located between the laser cutting head and the copper block.

2. The rail repair equipment according to claim 1, characterized in that: Each of the measurement modules includes a mounting bracket fixedly connected to the bottom of the vehicle body, the mounting bracket is in a "door"-shaped structure, and two contour measurement sensors are arranged at both ends of the mounting bracket, and the two contour measurement sensors are fixedly arranged on both sides of the rail at a fixed angle; An installation box is arranged at both ends of the outer end surface of the installation bracket, and four corrugation measurement sensors are arranged in each installation box. The four corrugation measurement sensors are located above the rail.

3. The rail repair equipment according to claim 1, characterized in that: Each of the transition processing modules comprises two second transverse guide rails and a second rack, and the two second transverse guide rails and the second rack are fixedly connected to the bottom of the vehicle body; the two second transverse guide rails and the second rack are slidably connected to two transition processing components; Each of the transition processing components includes a second transverse shift seat, on which a second upper slider, a second transverse motor and a second vertical motor are arranged; the second upper slider is arranged on the top of the second transverse shift seat and is slidably connected to the second transverse guide rail; The output shaft of the second horizontal motor is provided with a second gear meshing with the second rack; the second vertical motor is vertically arranged on the top of the second transverse displacement seat, the output shaft of the second vertical motor is connected with a second lead screw through a second coupling, the second lead screw is threadedly connected with a second lead screw nut, the second lead screw nut is connected with a second vertical sliding seat, and the second vertical sliding seat is slidably connected with the second transverse displacement seat through a second lower slider and a second vertical guide rail; Two transition brackets are fixedly connected to the bottom of the second vertical sliding seat, a first movable seat is rotatably arranged between the two transition brackets, a first rotating oil cylinder is transversely arranged on the outside of one of the transition brackets, and the rotating shaft of the first rotating oil cylinder passes through the transition bracket and is fixedly connected to the first movable seat, driving the first movable seat to rotate circumferentially; A first center hole is provided on the first movable seat, a first grindstone seat is provided in the first center hole, the first grindstone seat can slide up and down along the first center hole, a first clamping cylinder is provided on the first movable seat, the piston rod of the first clamping cylinder is fixedly connected to the first grindstone seat, and is used to push the first grindstone seat to slide; a driving motor is provided at the rear end of the first grindstone seat, the stator part of the driving motor is fixed to the first grindstone seat, the rotor part of the driving motor is connected to a connecting shaft, the connecting shaft passes through the first grindstone seat, and the end of the connecting shaft is connected to the first grindstone.

4. The rail repair equipment according to claim 3, characterized in that: The ends of the two transition brackets are connected to a transition connection seat, and the two transition connection seats are respectively provided with a first rotary cylinder and a first rotary encoder; a bearing and a sleeve are provided between the connecting shaft and the first grindstone seat.

5. The rail repair equipment according to claim 1, characterized in that: The ride comfort recovery module comprises a support frame, and a traction rod is arranged on both sides of the support frame, and two ends of each traction rod are respectively hinged to the side wall of the support frame and the bottom of the vehicle body; A plurality of downward pressure cylinders are vertically arranged on the support frame, and the fixed ends of the plurality of downward pressure cylinders are fixedly connected to the bottom of the vehicle body, and the piston ends are fixedly connected to the support frame, and the bottom of the support frame is provided with guide wheels for cooperating with the rails; a plurality of groups of first guide shafts and a plurality of linear reciprocating cylinders are arranged on the support frame, and each group of the first guide shafts is matched with one linear reciprocating cylinder, and the number of each group of first guide shafts is two, and the first guide shafts and the linear reciprocating cylinders are both arranged along the length direction of the vehicle body, and a smoothing operation component is connected to the two first guide shafts through a first guide shaft slider, and each linear reciprocating cylinder is a bidirectional operating hydraulic cylinder, and the bidirectional output shafts of the linear reciprocating cylinders are fixedly connected to the smoothing operation component, and the fixed end of the linear reciprocating cylinder is fixedly connected to the support frame, and a plurality of the second grinding stones are arranged on the smoothing operation component.

6. The rail repair equipment according to claim 5, characterized in that: Each of the smoothness operation components includes a main frame fixedly connected to the first guide shaft slider and the bidirectional output shaft of the linear reciprocating cylinder at the top, a plurality of second guide shafts and a plurality of linear cylinders are arranged on the main frame, the second guide shafts and the linear cylinders are in a one-to-one matching relationship, the axial direction of each second guide shaft and the extension and contraction direction of the piston rod of the linear cylinder are perpendicular to the length direction of the rail, a connecting frame is slidably connected to each second guide shaft through the second guide shaft slider, and the output end of the linear cylinder is fixedly connected to the second guide shaft slider; a second rotating cylinder and a transition seat are connected to the bottom end of the connecting frame, a second movable seat is connected to the piston rod of the second rotating cylinder, a second rotary encoder is arranged on the transition seat, and a rotating shaft of the second rotary encoder is fixedly connected to the second movable seat; A second center hole is provided on the second movable seat, a second grindstone seat is provided in the second center hole, the second grindstone seat can slide up and down along the second center hole, a second clamping cylinder is provided on the second movable seat, the piston rod of the second clamping cylinder is fixedly connected to the second grindstone seat for pushing the second grindstone seat to slide, and the second grindstone is provided at the bottom of the second grindstone seat; a plurality of second grindstones are respectively arranged on both sides and the top of the rail.

7. A repair method for the rail repair equipment according to any one of claims 1 to 6, characterized in that: include: Step 1: The vehicle body moves in the working direction, and the measuring module located in the front of the driving direction synchronously measures the profile and corrugation of the rail, transmits the profile and corrugation data of the rail to the control system and generates a profile repair plan; Step 2: The vehicle body drives the profile repair module to move to the defective position of the rail, and the laser cutting head on the profile repair module is adjusted to a specified angle to cut the defective position of the rail according to the profile repair plan; Step 3: The vehicle body drives the transition processing module located at the rear of the profile repair module to move to the rail laser cutting position, and the transition processing module is started to rotate the first grindstone to grind the rail laser cutting position to remove the heat affected zone of the rail after laser cutting, and at the same time form a grinding mark with a fixed angle with the length direction of the rail, thereby increasing the grinding amount of the smoothness recovery module; Step 4: The vehicle body drives the smoothness recovery module located at the rear of the transition processing module to move to the rail grinding position, and the smoothness recovery module is started to make the second grinding stone reciprocate and linearly move to grind the rail grinding position to restore the smoothness of the rail; Step 5: The transition processing module and the profile repair module located at the rear of the smoothness recovery module do not work, and the measurement module located at the end measures the processed rails again to evaluate the quality of the rail repair operation and complete the rail repair operation.

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